Ketonic epoxides



United States PatentO KETONIC EPOXIDES Tracy M. Patrick, Jr., Dayton, Ohio, assiguor to Monsanto Chemical Company, St. Louis, Mo., a corporation of Delaware Application January 19, 1953, Serial No. 332,095

11 Claims. (Cl. 260-348) No Drawing.

RCHO nCHICH.CH.CHz.O

in which R is an alkyl radical of from l to 17 carbon atoms and n is an integer of from 2 to 20.

Saturated aldehydes which may be employed according to theinvention are, for example, acetaldehyde, propionaldehyde, n-butyraldehyde, isobutyraldehyde, n-valeraldehyde, is ovaleraldehyde, methylethylacetaldehyde, ncaproic aldehyde, isohexaldehyde, Z-ethylhexaldehyde, capric aldehyde, undecaldehydalauric aldehyde, palmitic aldehyde, stearicaldehyde, etc. i j The invention also provides a method of preparing no only the adducts of the above formula, but also a means of. preparing ketonic compounds containing only one epoxide gr oup Thus, I have found that one mole of butadieneoxide adds to one mole of the aliphatic aldehyde as follows:

'RCHO OHz:OH.CH.CHz.O RCOOHiCHzCHCHnQO Previously, such ketonic epoxides were obtainable only by oxidation of difiicultly obtainable olefinic ketong.

The 1:1 addition products, i. e., 1-acyl-3,4-epoxybutanes in which the acyl radical is aliphatic and contains from 2 to 18 carbon atoms, are compounds which are advantageously employed as lubricant additives, synthetic resin plasticizers, etc. They areparticularly useful as intermediates for the preparation of otherwise difiicultly obtainable hydroxy ketones. The 1:2-20 aldehyde butadiene monoxide adducts are particularly valuable as anti-foaming agents for hydrocarbon oils. As disclosed iii the copending application of Joseph E. Fields, Serial No. 195,898, filed November 15, 1950, now Patent No. 2,644,794, these higher adducts have the property of reducing or completely inhibiting formation of foam or froth in base stock or compounded hydrocarbon oils.

According to the present process, the aldehyde is contacte'dwith butadiene monoxide in the presence of a free radical-liberating agent as catalyst, and the resulting, mixture is allowed to stand at ordinary or increased temperatures until formation of the liquid mixture of adducts. has occurred; Theresulting reaction mixture may con-.

2,720,530 Patented Oct. 11, 1955 tain some unreacted initial material, 1:1 adduct and higher adducts. The unreacted material and then the 1:1 adduct may be separated from the mixture by fractional distillation. The residue is a liquid mixture of adducts in which one mole of the aldehyde is combined with from 2 to 20 moles of butadiene monoxide. The reaction may be effected by mixing together the aldehyde, the oxide and the catalyst and maintaining the resulting mixture, advantageously with agitation, at a temperature which permits steady decomposition of the catalyst and consequent steady liberation of acyl free-radicals.- Or, if desired, the butadiene monoxide may be added gradually, e. g., dropwise, to the aldehyde while constantly maintaining an optimum quantity of active catalyst in the reaction zone, which zone is preferably kept at a temperature conducive to the formation of free-radicals. Depending upon the nature of the individual aldehyde and catalyst and the properties desired in the final product, increased temperatures, e. g., temperatures of from above room temperature to about C. may be generally employed. The reaction time may vary from, say, several hours, to several'days. Substantially equimolar quantities of the aldehyde and butadiene monoxide may be used; however, for the production of the present adducts in good yields an excess of the aldehyde is pre ferred. Catalyst quantities of upto 5 per cent, based on the weight of the oxide may be used.

Formation of the present adducts probably proceeds through a chain mechanism, with termination of the chain at an early stage, i. e., at a point at which probably no more than 20- moles of butadiene monoxide have added to one mole ofthe aldehyde. Depending upon the nature and the quantity of the aldehyde and of freeradical-liberating agent, as well as upon the reaction conditions, chain propagation may be terminated at various stages to yield mixtures of products in which from 1 to 20 moles of the oxide have added to one mole of the aldehyde,

. An extraneous, inert solvent or diluent, e. g., benzene or hexane may be employed, either to serve as catalyst solvent, to mitigate reaction heat, or dilute the concentration of the oxide in the reaction mixture. The use of such a solvent or diluent, however, is generally of little economic advantage.

Free-radical-liberating agents which may be employed in promoting addition of butadiene monoxide tothe saturated aliphatic aldehydes are compounds which will decompose to give free radicals. Such compounds include peroxygen-type catalysts, for example acyl peroxides such as acetyl,.benzoyl, lauroyl, or stearoyl peroxides; hydrocarbon peroxides or hydroperoxides such as di-tert-butyl peroxide, di-tert-amyl peroxide, tert-butyl hydroperoxide, cumene hydroperoxide or p-cymene hy.-,

droperoxide; and inorganic per-compounds such as hydrogen peroxide, sodium peroxide, sodium perborate; potassium persulfate, and alkali percarbonates; hydrazine derivatives such as hydrazine hydrochloride and dibenzoyl hydrazine; organometallic compounds such as tetraethyl lead, etc. For convenience, the peroxygen-type catalysts will be hereinafter referred to as peroxidic com-. pounds. Only catalytic quantities of the free-radical liberating agent need be employed in promoting the addition reaction. Quantities of as little as 0.001 per cent to 1.0 per cent, based on the weight ofthe oxide are generally sufiicient to give optimum yields of the present adducts. In order to. avoid detrimental side reactions,

quantities of more than 5 per cent of the catalyst, based on the weight of the oxide should not be employed.

Ultra-violet light may be employed with the catalyst or as the sole catalytic agent. n

The invention is further illustrated, butnot limited, by the following examples:

Example 1 A mixture consisting of 35 g. (0.5 mole) of butadiene monoxideand 108 g. (1.5 mole) ofn-butyraldehyde was brought to refluxing temperature (712 C.-) and 0.5 g. of ben'zoyl peroxide was then added. The resulting reaction mixture was maintained at a'temperatu're of from 71.2 C. to 74 C. for 40.5 hours. During this time, two additional 0.5 g. portions of benzoyl peroxide were added to the reaction mixture (at the end of 16.5 hours and at the end of 24.5 hours, respectively). Unreacted material was removed by distilling the product up to 75? C. at atmospheric pressure, and further fractionation under partial vacuum gave the substantially pure 1:1 adduct, 7,8-epoxy-4-octanone, B.- P. 59- 73 C./l mm. (mostly 623 C./10 mm.) n 1.469. The residue was a liquid mixture of adducts of. one mole of n-butyraldehyde with 2 to 20 molesof butadiene monoxide.

Example 2 This example is like Example 1, except that a longer heating time and greater quantities of reactants were employed. The reaction mix'ture, consisti'ngof2l6 g. (3.0 moles) of n-butyraldehyde, 70 g. (1.0 mole) of butadiene monoxide and 2.0 g of benzoyl peroxide was maintained at a temperature of about 74 C. for 68.5 hours. During this time an additional 1.5 g. of'catalyst was added to the reaction mixture. Unreacted initial material was removed from the product; and the residue, consisting of a liquid mixture of adducts inwhich one mole of nhutyraldehyde is combined with from 1 to 20' moles of butadiene monoxide was distilled to yield a fraction 3. P 30 C.81 C./ 10 mm., 1, 1.4562 comprising chiefly the 1:1 butyraldehyde-butadiene monoxide ad: duet and as residue a liquid mixture, 2 1.4918, of adducts of one mole of the aldehyde with'from 2 to 20 moles of butadiene monoxide. As shown in Example 3, the mixture of higher adducts is a very active defoaming agent. v

. Example 3 This example shows the antifoarning efiicacy of the mixture of adducts, B. P. above 81 C./1-0 mm-., prepared in Example 2 and-also provides a comparison of these" higher ketonic epoxy compounds with a known low-molecular weight epoxy ketone, 5,6'-epoxy-6'-methyl- Z-he'ptah'on'e.

The following testing procedure was used: I 1 Cha'mPlinBO base oil (25 cc.) was placed in a 100- m1; graduated cylinder in the top of which was inserted a two-hole rubber stopper. A nitrogen-inlet tube extended through this stopper, to the bottom of which was attached a gas 'diffuser. The length of the inlet tube was adjusted so that when the apparatus was assembled, the I diffuser just touched the bottom of the cylinder. The cylinder was maintained in an oil' bath capable of con trolling temperature at 200il F., (93.3i0.6' 6.), and large enough to permit the cylinder to be immersed at least to the 90-ml. mark. Nitrogen was supplied to the cylinder at the rate of 012 cubic feet per hour, employing a calibrated flowmeter. Each test sample was heated to 120 F. (48.9 C.) and then-cooled, beforetes'ting, to 75i5 F. (23.9i2.8 C.) in a constant temperature roorn. With the nitrogen hose disconnected between the flowm'eter and the delivery tube to thediffusen the' latter-"was allowed to soak in the oil" for 5 minutes, at theendof which time the nitrogen flow was started through the diffuser. Reading's of the top and bottom foam-levels were taken at-the end ofa S rn'i'nu'te period.

Thev volume of foam was calculated from the two readings.

' Employing-the above-described testing procedure; there was determined the antifoaming effects or said 5,6-

epoxy-6-methyl-2-heptanone and said mixture-of adducts,

respectively, when added to the oil. in the concentrations shown below. The following results were obtained:

.. Concentration of Foam, 00., Agent Tested Test Samat 5 Minple, Weight utes Percent Blank 50 5,6-epoxy-fi-methyl-aheptanone 0. 1 50 Do 0.2 50 0. 02, 10 0.025 2 0.03 none 0.05 none Operating as in Examples 1 and 2, other saturated, aliphatic aldehydes may be'similarly reacted with butadiene monoxide to give adducts in which one mole of the aldehyde has combined with from one to 20 moles of the oxide. Thus, butadiene monoxide adds to one mole of propionaldehyde to give 6,7-epoxy- 3 heptanone and adducts in which from 2 to 20 moles of butadiene monoxide are combined with one mole of propionaldehyde. n- Valeraldehyde similarly yields the 1:1 adduct, 1,2-epoxy- S-nonanone, and products in which from 2 to 20 moles of butadiene monoxide arecombined with one mole of nvaleraldehyde. Hexaldehyde with butadiene monoxide yields 1,2-epox-y-5-decanone and the higher ratio adducts and heptaldehyde gives 1,2-epoxy-5-undecanone and the higher addition products. a 6

The present aldehyde-butadiene monoxide adducts are viscous, highly stable liquids which are advantageoii'sly employed for a variety of industrial purposes. While adducts of one mole of the aldehyde with from 2 to 20 moles of the oxide are particularly valuable as antifo'a'rning additives to lubricants, they also find use as softeners for natural rubbers or synthetic rubbers such as the polymers and copolymers of 1,3-butadiene com pounds. Particularly useful as rubber softeners are 'the adducts of the lower aldehyde's, e. g., propionaldehyde' or bu'tyraldehyde with from 2 to 4' moles of butadiene monoxide. Especially useful as plasticizers for synthetic resins and plastics are the adducts of the higher aldehydes, e. g., lauric aldehyde with from 2 to 50 moles of butadiene monoxide. Adducts in which from-2 to 20 moles of the oxide have combined with one mole of the aldehyde possess very good viscosity characteristics; this together with their pronounced heat-stability and low volatility recommends them for use as viscosity-improving lubricant additives. The adducts of higher oxide: aldehyde ratio, i. e., those in which from 10 to 20 moles of butadiene monoxide have combined with one mole of the aldehyde have very good thickening properties and are advantageously employed as cosmetic bases, emulsifying agent's, etc.

What I claim is:

1. A liquid rnixture of adducts of butadiene monoxide and a saturated aliphatic aldehyde, said adducts having the formula Roo[om.c11.0rr.onl.(l ]n in which n is an integer of from 2 to 20 and R is an alkyl radical of from 1 to 17 carbon atoms.

2. A liquid mixture of adducts of butadiene monoxide and butyraldehyde, said adducts having the formula CHaCHzCHzCO[-CH1.$H.CH.CH2.6]H

in which I1 is an integer of from 2 to 20.

3. The process which comprises contacting butadiene monoxide, in the presence of a peroxidic free radicalliberating agent as catalyst, with a saturated aliphatic aldehyde having the formula RCHO in which R is an' alkyl radical of from 1 to 17 carbon atoms and recovering from the resulting reaction product an adduct in which one mole of the aldehyde has combined with from 1 to 20 moles of butadiene monoxide.

4. The process which comprises contacting butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, with a saturated aliphatic aldehyde having the formula RCHO in which R is an alkyl radical of from 1 to 17 carbon atoms and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde has combined with from 2 to 20 moles of butadiene monoxide.

5. The process which comprises contacting butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, with a saturated aliphatic aldehyde having the formula RCHO in which R is an alkyl radical of from 1 to 17 carbon atoms and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with one mole of butadiene monoxide.

6. The process which comprises contacting n-butyraldehyde with butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with from 2 to 20 moles of butadiene monoxide.

7. The process which comprises contacting propionaldehyde with butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with from 1 to 20 moles of butadiene monoxide.

8. The process which comprises contacting hexaldehyde With butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with from 1 to 20 moles of butadiene monoxide.

9. The process which comprises contacting n-valeraldehyde with butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with from 1 to 20 moles of butadiene monoxide.

10. The process which comprises contacting heptaldehyde with butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering from the resulting reaction product a liquid mixture of adducts in which one mole of the aldehyde is combined with from 1 to 20 moles of butadiene monoxide.

11. The process which comprises contacting nbutyraldehyde with butadiene monoxide, in the presence of a peroxidic free radical liberating agent as catalyst, and recovering 7,8-epoxy-4-octanone from the resulting reaction product. 

1. A LIQUID MIXTURE OF ADDUCTS OF BUTADIENE MONOXIDE AND A SATURATED ALIPHATIC ALDEHYDE, SAID ADDUCTS HAVING THE FORMULA
 3. THE PROCESS WHICH COMPRISES CONTACTING BUTADIENE MONOXIDE, IN THE PRESENCE OF A PEROXIDIC FREE RADICAL LIBERATING AGENT AS CATALYST, WITH A SATURATED ALIPHATIC ALDEHYDE HAVING THE FORMULA RCHO IN WHICH R IS AN ALKYL RADICAL OF FROM 1 TO 17 CARBON ATOMS AND RECOVERING FROM THE RESULTING REACTION PRODUCT AN ADDUCT IN WHICH ONE MOLE OF THE ALDEHYDE HAS COMBINED WITH FROM 1 TO 20 MOLES OF BUTADIENE MONOXIDE. 